Hot Air Circulation for Wave Soldering Machines

The present invention relates to soldering and soldering machines, and more specifically to a hot air circulation apparatus and method for wave soldering machines.

Wave soldering machines are typically used to solder components onto printed circuit boards. Such machines employ a fluxer for applying flux to the solderable surfaces of the printed circuit boards, preheaters to preheat the printed circuit boards, and a solder wave to apply liquid solder to the solderable surfaces. One such machine is manufactured by Electrovert, Inc.

The preferred flux used in wave soldering machines is a resin flux. Resin fluxes provide smooth finished surfaces. However, resin fluxes contain environmentally harmful and flammable volatile organic compounds.

An alternative to resin fluxes is a water-based flux, such as the 970 and 970CTX flux products from Kester Corporation. An air knife is typically located after the flux tank to remove excess flux from printed circuit boards and prevent dripping on preheater surfaces. A warm gentle airflow is required so as not to blow the flux off the board.

The water-based flux is environmentally safe, but when used in wave soldering machines suffers from the disadvantage that the water cools the printed circuit board and causes solder balls to form. Previous attempts at making the water-based flux usable in wave soldering machines have been unsuccessful.

Therefore, it would be desirable to provide an apparatus and method that would allow wave soldering machines to use the water-based fluxes.

In accordance with the teachings of the present invention, a hot air circulation apparatus and method for wave soldering machines is provided. The hot air circulation apparatus heats air from a high-pressure air source and directs it at the flux applied to a printed circuit board. The heated and pressurized air also circulates air within the wave soldering machine to force the moisture out. A plurality of hot air knives are mounted adjacent heaters within the wave soldering machine and are coupled to the pressurized air source. The hot air knives include a hollow cylindrical metal device which conducts heat from the heater, and which contains a plurality of orifices which increase the pressure of the air and direct the air at the flux.

It is accordingly an object of the present invention to provide a hot air circulation apparatus and method for wave soldering machines.

It is another object of the present invention to provide a hot air circulation apparatus and method for wave soldering machines which forces heated and pressurized air against the water-based flux and into the chamber to dry the flux and remove the moisture.

It is another object of the present invention to provide a hot air circulation apparatus and method for wave soldering machines which is easy to retrofit into existing wave soldering machines.

Additional benefits and advantages of the present invention will become apparent to those skilled in the art to which this invention relates from the subsequent description of the preferred embodiments and the appended claims, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a diagrammatic view of a wave soldering machine employing the apparatus of the present invention; and

FIG. 2 is a perspective view of an air knife.

Referring now to FIG. 1, a wave soldering machine 10 employing the hot air circulation apparatus 12 of the present invention is shown. Wave soldering machine 10 also includes tunnel chamber 14, conveyor 16, fluxer 20, heaters 22 and 24, and solder pot 26.

Conveyor 16 carries printed circuit boards 18 through tunnel chamber 14. Printed circuit boards 18 have components mounted thereon whose electrical contacts have previously been coated with solder bumps. Preferably, the flux applied by fluxer 20 is number 970 or 970CTX from Kester Corporation. Number 970CTX includes a special wetting agent to allow the flux to evenly spread. Heaters 22 and 24 preheat printed circuit boards 18 as they pass overhead. Solder pot 26 applies liquid solder and removes any excess flux from printed circuit board 18 and its components.

Hot air circulation apparatus 12 includes hot air knives 28, connectors 29, hoses 32, and high-pressure air source 30.

Hot air knives 28 apply high pressure, high-temperature air to dry the flux and to drive the moisture from the flux out of tunnel chamber 14. Hot air knives 28 are preferably mounted on heaters 22 and 24, thereby making installing and retrofitting hot air circulation apparatus easy. However, other mounting configurations for hot air knives 28 are envisioned by the present invention, which may include additional heaters. Preferably, hot air knives 28 are made of aluminum so as to rapidly conduct heat from heaters 22 and 24 to the high-pressure air rushing through knives 28. The first group of hot air knives 28 on heaters 22 tends to dry the flux, while the second group of knives on heater 24 tends to circulate and dry the air in tunnel chamber 14. Four hot air knives 28 on each of heaters 22 and 24 are preferred.

Hot air knives couple to high-pressure air source 30 through hoses 32 and connectors 29. Ordinary high-pressure air connectors and hoses may be employed. Preferably, high-pressure air source provides about 90 psi, which ensures adequate drying and circulation.

Turning now to FIG. 2, hot air knife 28 is shown in more detail. Air knife 28 is simply constructed, starting with a metal pipe, preferably aluminum. For the machine manufactured by Electrovert, Inc., a 0.400 inch outside diameter pipe with a thickness of about 0.070 inches and a length of about 24 inches is preferred. A standard end cap 46 is screwed onto end 44. At the other end 40, knife 28 has inside threads 42 for receiving connector 29.

With both ends 40 and 44 sealed, air from hot air source 30 passes through orifices 48, which are evenly spaced and oriented in a line along surface 50 of knife 28, perpendicular to the direction of travel of printed circuit board 18. Preferably, orifices 48 are about 0.300 inches on center apart, with the first orifice being about 1.5 inches from end 40. Orifices 48 are preferably 0.05 inches in diameter for about 90 psi. For this orifice diameter and input pressure, adequate circulation pressure and air flow volume are provided to drive moisture from tunnel chamber 14.

Although the present invention has been described with particular reference to certain preferred embodiments thereof, variations and modifications of the present invention can be effected within the spirit and scope of the following claims.